Specifications

Part number 550-100-090/0809
111
g a s -f i r e d w a t e r b o i l e r — Boiler Manual
MAINTENANCE & SPECIFICATIONS
Maintenance (continued)
Accessing & cleaning exchanger: Ultra-155,
-230, 299 and -399 Only
Close the external manual gas valve.1.
Disconnectwiring:•gasvalveelectricalplug•twoelectricalMolex2.
plugsfromtheblowerassembly•ignitioncable•groundwire.
Disconnect the flexible gas line at its flare fitting.3.
Remove the air silencer by lifting the plastic clamp off of the gas line 4.
and then gently sliding the air silencer down and off the valve.
Remove hex head nuts (10mm box end wrench) from heat ex-5.
changer cover plate and remove burner cover plate from heat
exchanger.
Pull the entire blower/venturi/gas valve/cover plate assembly out 6.
of the boiler. (See Replacement parts section for component iden-
tification and locations.)
Remove three M4 hex head screws (7mm box end wrench) and 7.
burner clips securing burner to cover plate. Remove cover plate.
Use a vacuum cleaner to remove any accumulation on the heating 8.
surfaces. Do not use any solvent.
If the vacuum cleaner is unable to clean completely, wash the heat-9.
ing surfaces with clean, warm water. If further cleaning is necessary,
use the Heat Exchanger Cleaning Tool (see Replacement parts at the
end of this manual) or a piece of 20-gauge or lighter sheet metal
¾” wide by about 18 inches long to loosen deposits. See Figure 114.
See water spraying notice.
Inspect the heat exchanger cover plate insulation and gasket. Re-10.
place if damaged. Read the ceramic fiber WARNING on page 93
before handling or disposing of ceramic fiber materials.
Replace the burner, hex head screws and burner clips removed in 11.
step 7. See Figure 107, page 96.
Place cover plate gasket in groove of heat exchanger cover plate. 12.
Replace cover plate.
Reinstall hex head nuts on the cover plate mounting studs and 13.
tighten in a staggering pattern until cover plate is uniformly
tightened.
You must gradually tighten the cover plate nuts. For
Ultra-155 through -399, follow the tightening sequence
shown in Figure 115, making two or three passes with
a torque wrench. The final torque MUST NOT exceed
50 inch-pounds, +/- 10 inch-pounds.
Reinstall air silencer by sliding on gas valve venturi and securing 14.
clamp to gas line.
Reconnectwiring:•gasvalveelectricalplug•twoelectricalMolex15.
plugsfromtheblowerassembly•ignitioncable•groundwire.
Reconnect the flexible gas line and gas valve electrical plug.16.
Perform a soap suds leak test on all interior gas piping after start-17.
ing the boiler.
Cleaning the heat exchanger — water side (ALL
models)
Follow the procedure given in 1. “Clean the cast aluminum heat ex-
changer when required — water side,” page 109 to clean the water
side of the exchanger.
Follow the complete procedure for boiler and system start-up, 2.
beginning on page 31.
Nut tightening sequence — Figure 115
155 to 399 — Gradually tighten the
nuts, repeating the sequence shown
below until the torque reaches 50
inch-pounds (+/- 10 inch-pounds)
WATER SPRAY HEAT EXCHANGER
PINS AFTER USING CLEANING TOOL
After using the cleaning tool as shown in 1. Figure 114,
spray water downward from above the pins to flush
remaining sediment.
Remove sediment from the bottom of the heat 2.
exchanger.
Then disconnect the condensate line at the bottom 3.
of the heat exchanger.
Loosen the hose clamps at both ends of the a.
condensate line.
Remove the line and place a pan under the trap b.
connection.
Spray water into the bottom of the heat ex-c.
changer to flush remaining sediment to the
condensate outlet.
Spray water through the condensate line to d.
clean it thoroughly.
Remove pan and replace the condensate line.e.
Follow instructions on f. page 110 or page 111
to check components and replace burner and
cover.